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As-built documentation Experiences and development

As-built documentation Experiences and development. Herman Baets Manager Technical Governance. Infrastructure. Total site area .................................................................... 598 ha Number of plants ..................................................................... 54

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As-built documentation Experiences and development

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  1. As-built documentationExperiences and development Herman Baets Manager Technical Governance PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  2. Infrastructure Total site area .................................................................... 598 ha Number of plants ..................................................................... 54 Capacity tank farm ....................................................... 446.000 t Quay length ..................................................................... 4.551 m Roads .............................................................................. 152 km Railtracks ............................................................................ 41 km Overground pipes ............................................................. 290 km Underground pressure pipes ……………………………. 230 km PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  3. BASF Antwerpen N.V.Some technical figures Replacement value……………………………………..+/- 6,4 bn € Amount of dynamic equipments……………………………..19.000 (pump, motor, turbines, fans,…) Amount of static equipments…………………………………15.000 (vessels, heat exchangers,storage tank,…) Amount of control loops…..…………………………………..35.000 Energy consumption • Electrical ca. 370 MW= ca. 5% Belgian consumption • Steam ca. 500t/h = heating of 10.000 houses PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  4. The Belgium-Netherlands Chemical cluster R'dam-Botlek R'dam-Pernis Exxon Mobil Lyondell Chemie Shin-Etsu Shell Shin_Etsu Netherlands Basell Polyolefins Dow Moerdijk Europoort-Terminal Exxon Mobil Shell ELLBA Rozenburg Huntsman-ICI Basell Polyolefins Meerhout Geel Exxon Mobil BP Chemical Geleen DSM Germany Antwerp Ostend Terneuzen BASF Atofina Antwerp Bayer/Lanxess Solvay/Solvin Exxon Mobil Ineos-Phenol Borealis Degussa-Hüls Zwijndrecht Dow Beringen Bayer/Lanxess Borealis Ineos-Oxide Borealis Beek Tessenderlo LVM Tessenderlo Chemie/LVM Dow Feluy Atofina BASF BP Chemical Polimeri Steam Cracker Jemeppe Ethylene Pipeline Solvay/ Solvin Propylene Pipeline Belgium < 2 Mil. t/y 2-6 Mil. t/y 6-10 Mil. t/y France > 10 Mil. t/y PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  5. Air Liquide Industries Belgium ARCH Chemicals Atofina Chemicals BASF Antwerpen Bayer Antwerpen / Lanxess BP Chemical BF Goodrich BP Solvay PE Europe Borealis DegussaAntwerpen Eval Europe Exxon Chemical Belgium Ferro Fina Antwerp Olefins Haltermann (DOW) Chemical companies in the Antwerp Harbour and the Campine 1/3 of the Belgian Chemical Industry In both these regions Antwerpen Hercules Belgium Indaver INEOS-Phenol INEOS-Oxide Lanxess Rubber 3M Belgium Monsanto Europe Nippon Shokubai NSP Olefins Phillips Petroleum Chemicals Praxair Production Solvay / SolVin Reilly Union Carbide Benelux Witco Benelux BP Chembel BF Goodrich Chemical Exxon Chemical Belgium Kaneka Belgium Oleon ICI Belgium Janssen Pharmaceutica Phillips Petroleum Soudal Sanico Tessenderlo Chemie- LVM Praxair Trans Furans Chemicals Borealis Polymers DOW Belgium 5 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  6. Why As-Built is a general issue ? Do laws exist, where “keeping douments/data as-built” is required ? NO ! Why this is an issue ? PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  7. Why As-Built is a general issue ?Risk management • Government forces nothing ! • The society moves to risk management • European regulations follow this idea • Economical • Social • The local government as representant of the society are adapting this ideas in their laws Our objective: Be prepared so that we can prove that we manage our risks. Which data/documentation do we need to fulfill the requirements ? PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  8. BASF AntwerpenWhy “As-built” is an issue ? • Analyze of the document/data strategy • Create the process to keep it up to date • Intelligent and pragmatic • Criticality according to the European regulations • Risk management • Design of the document/data management system The Ibanx initiative As-built Best Practice PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  9. General Objectives of As-built BP ? • Facilitation of the agreement in the different companies about • the content of as-built technical documentation/data • how far good quality and availability pushes company business results. • Agreement leads to optimal decisions about technical documentation/data • About the necessary resources (men, money, system) • The required quality • The necessary availability. • The drive for realisation and maintenance PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  10. As-built BPWho ?20 Plant Owners have contributed NL ENERGIE CHEMBEL E&P PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  11. The As-built BPHow ? • Mapping methodology supported by typical examplary documents • Evaluation of the criteria • Engineering, operations/maintenance • Legal requirements (ATEX, PED, AREI, ARBO, Seveso, BRZO,. ) • Result: As-Built data base • 99 document types according to STEP LIB • 83 elektronical examples • 105 related documenttypes by the participants) • 4713 data as-built (yes/no) and why PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  12. As-built BPSynthesis of the workshopsTopics • Process • Hazard/Risk • Operations/maintenance • Spatial Plant lay-out: 3D • Equipment • Physical data • Logical data • Specifications Total: 23 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  13. Synthesis of the workshopsProcess • Process flow diagram (PFD) • process data sheet • Piping and instrumentation diagram (PID) • electrical load list • equipment list • line list • instrument list • Functional control and logic diagram • Alarm and trip settings list • Piping isometric drawing (according PED) PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  14. Synthesis of the workshopsHazard/Risk • Emergency equipment and exits layout • Hazard and effects register • register of safety devices • Risk analysis • ATEX-certificate PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  15. Synthesis of the workshopsOperations/maintenance • Maintenance and inspection plan • Maintenance manual • Operating manual PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  16. Synthesis of the workshopsSpatial Plant lay-out: 3D • Plot plan • lightning and grounding layout • fire and gas protection equipment location drawing • road and drainage layout • civil and structures general arrangement drawing • equipment location plan • building layout sections and elevations • instrument location layout • area classification layout • Underground services layout PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  17. Synthesis of the workshops Equipment: physical data • Assembly drawing • equipment data sheet • general arrangement drawing • construction drawing • certificate of conformance • Instrument data sheet • Spare parts list • parts list • Valve data sheet PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  18. Synthesis of the workshops Equipment: logical data • I/O list • Loop diagram • control logic diagram • cause and effect chart • single line diagram • connection diagram • cable list • isometrics overall electrical tracing • lighting and power layout • plc configuration diagram • control schematic diagram PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  19. Synthesis of the workshops Specifications • Insulation specification • Material specification • Piping specification PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  20. The As-built BPNext steps • Presentation on the PELC • A Working group (AB-BP) creates the publication • Objective: Text ready 9/2006 • Participants: Members of the companies who participated • Facilitation/coördination: IBANX • Brainstorming further actions • Keep the BP up to date • E.g.: What is document/data, linked to the procedure ? • Publication on the USPI-website PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

  21. Thanks for listening Questions ? E-mail: herman.baets@basf.com Tony.houthaeve@basf.com PELC conference 2006 - Herman Baets BASF Antwerpen N.V.

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